Modular Enclosure

ABSTRACT

An enclosure includes a plurality of modular corner segments and a plurality of modular wall segments that connect together to at least partially define an internal compartment of the enclosure. The wall segments extending lengths between opposite free ends. At least a majority of the wall segments are fabricated from a polymer. Each corner segment includes opposite first and second receiver sockets that are each configured to receive a corresponding free end of a corresponding wall segment therein to connect the corner segment to the corresponding wall segments. At least a majority of the corner segments are fabricated from a polymer. The corner segments and the wall segments connect together to define the internal compartment of the enclosure.

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates generally to modularenclosures.

Modular enclosures are known for containing electrical devices (such ascircuit boards, actuators, avionics, automotive electronics, and/or thelike) and non-electrical devices. For example, many avionics componentslocated on-board aircraft and many automotive electronic componentslocated on-board automobiles are housed in modular electronicsenclosures. Known modular electronics enclosures include conventionalrail and panel boxes that are built using modular corner rails thatinclude two opposite receivers for receiving two modular side panels. Aplurality of side panels and corner rails are connected together tobuild the finished enclosure.

Known modular electronics enclosures are not without disadvantages. Forexample, known modular electronics enclosures such as rail and panelboxes may include a relatively large number of joints, which maydecrease a rigidity of the enclosure. Moreover, differently configuredmolds, extrusion dies, and/or the like may be required to fabricate themodular components of known enclosures that have different sizes and/orshapes, which may increase the cost and/or production time of such knownenclosures. Further, at least some known modular electronics enclosuresare fabricated from metals, which add weight to such enclosures. Knownmodular electronics enclosures may also have difficulty providing coversthat adequately close open ends, tops, and/or bottoms of the enclosure.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, an enclosure includes a plurality of modular cornersegments and a plurality of modular wall segments that connect togetherto at least partially define an internal compartment of the enclosure.The wall segments extending lengths between opposite free ends. At leasta majority of the wall segments are fabricated from a polymer. Eachcorner segment includes opposite first and second receiver sockets thatare each configured to receive a corresponding free end of acorresponding wall segment therein to connect the corner segment to thecorresponding wall segments. At least a majority of the corner segmentsare fabricated from a polymer. The corner segments and the wall segmentsconnect together to define the internal compartment of the enclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective view of an exemplary embodiment of an enclosure.

FIG. 2 is a perspective view of an exemplary embodiment of a modularconstruction unit of the enclosure shown in FIG. 1.

FIG. 3 is another perspective view of the construction unit shown inFIG. 2 viewing the construction unit from a different angle than FIG. 2.

FIG. 4 is a perspective view of an exemplary embodiment of anothermodular construction unit.

FIG. 5 is an exploded perspective view of an exemplary embodiment of az-axis section of the enclosure shown in FIG. 1.

FIG. 6 is a perspective view of the z-axis section shown in FIG. 5illustrating the z-axis section in an assembled state.

FIG. 7 is a perspective view of an exemplary embodiment of a modularextension construction unit.

FIG. 8 is an exploded perspective view of an exemplary embodiment ofanother z-axis section of the enclosure shown in FIG. 1.

FIG. 9 is a perspective view of the z-axis section shown in FIG. 8illustrating the z-axis section in an assembled state.

FIG. 10 is an exploded perspective view of the enclosure shown in FIG.1.

FIG. 11 is a perspective view of a portion of another exemplaryembodiment of a z-axis section.

FIG. 12 is an exploded perspective view of the z-axis section shown inFIG. 11.

FIG. 13 is a perspective view of a portion of the z-axis section shownin FIGS. 11 and 12 illustrating an exemplary embodiment of an externalmounting feature of the z-axis section.

FIG. 14 is a perspective view of yet another exemplary embodiment of az-axis section.

FIG. 15 is a perspective view of an exemplary embodiment of an enclosurebuilt using the z-axis section shown in FIG. 14.

FIG. 16 is a perspective view of another exemplary embodiment of anenclosure.

FIG. 17 is an exploded perspective view of the enclosure shown in FIG.16.

FIG. 18 is a perspective view of an exemplary embodiment of a modularextension construction unit.

FIG. 19 is a plan view of an exemplary embodiment of a z-axis sectionthat includes an exemplary embodiment of a partition.

FIG. 20 is a perspective view of an exemplary embodiment of a partitionconstruction unit of the z-axis section shown in FIG. 19.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is perspective view of an exemplary embodiment of an enclosure10. The enclosure 10 includes a plurality of sidewalls 12 and aninternal compartment 14 defined between the sidewalls 12. In theexemplary embodiment, the enclosure 10 is configured to enclose one ormore electronic devices 16 (explicitly shown in FIGS. 6 and 10) that arereceived within the internal compartment 14. But, the enclosuresdescribed and/or illustrated herein are not limited to enclosingelectronic devices. Rather, the enclosures described and/or illustratedherein may enclose any structure, device, material, and/or the like andany combination different structures, devices, materials, and/or thelike, such as, but not limited to, electronic devices, mechanicaldevices, chemicals, chemical devices, optical devices, acoustic devices,nuclear devices, and/or the like. In the remainder of the DetailedDescription, the enclosure 10 will be referred to as “electronicsenclosure 10”.

The electronics enclosure 10 may hold any number of electronic devices16 and each electronic device 16 may be any type of electronic device,such as, but not limited to, circuit boards, actuators, avionics,automotive electronics, vehicle electronics, electrical power supplies,electrical power distribution components, electrical power distributionsystems, antennas, controllers, processors, memories, storage devices,communication components, communication systems, passive electronicdevices, active electronic devices, and/or the like.

A coordinate system is labeled in FIG. 1. The electronics enclosure 10extends a width along an x-axis of the coordinate system, a length alonga y-axis of the coordinate system, and a height along a z-axis of thecoordinate system. The electronics enclosure 10 is defined by aplurality of z-axis sections 18 that are arranged within a stack 20along the z-axis, as is shown in FIG. 1. Specifically, the z-axissections 18 are stacked on top of each other along the z-axis to definethe height of the electronics enclosure 10. The stack 20 includes endz-axis sections 18 a and 18 b that define respective ends 22 and 24 ofthe height of the electronics enclosure 10. One or more interior z-axissections 18 c are positioned within the stack 20 between the end z-axissections 18 a and 18 b. Although three are shown, the electronicsenclosure 10 may be defined by (i.e., may include) any number of z-axissections 18. In some embodiments, the electronics enclosure 10 isdefined by only a single z-axis section 18. Each of the z-axis sections18 may be referred to herein as a “first”, a “second”, and/or a “third”z-axis section. Moreover, each of the z-axis sections 18 may be referredto herein as an “additional” z-axis section.

Optionally, one or more of the z-axis sections 18 includes a cover 26that defines a boundary of the internal compartment 14 of theelectronics enclosure 10. Specifically, while the sidewalls 12 definex-axis and y-axis boundaries of the internal compartment 14, the cover26 defines a z-axis boundary of the internal compartment 14. In theexemplary embodiment of the electronics enclosure 10, both of the endz-axis sections 18 a and 18 b within the stack 20 includes a respectivecover 26 a and 26 b. The cover 26 b is not visible in FIG. 1, but can beseen in FIGS. 8-10. The cover 26 a of the end z-axis section 18 adefines a z-axis boundary at the end 22 of the electronics enclosure 10,while the cover 26 b of the end z-axis section 18 b defines a z-axisboundary at the opposite end 24 of the electronics enclosure 10.Optionally, one or more active devices (not shown) are mounted on and/orincorporated into the cover 26 a and/or one or more active devices aremounted on and/or incorporated into the cover 26 b. The active devicesare accessible along the exterior of the electronics enclosure 10.Examples of such active devices include, but are not limited to,displays, membrane switches, enunciators, and/or the like.

As will be described below, each z-axis section 18 of the electronicsenclosure 10 is defined by a plurality of modular construction units 28.Specifically, a plurality of the construction units 28 connect togetherone after the other with a chasing symmetry to form a z-axis section 18.The construction units 28 and the z-axis sections 18 define nearfinished components that can be used as building blocks to construct anenclosure of arbitrary size from a set of near finished components usedrepetitiously. Each of the construction units 28 includes a wall segment30 and a corner segment 32. The wall segments 30 of the constructionunits 28 define the sidewalls 12 of the electronics enclosure 10. Theconstruction units 28 are described in more detail below with referenceto FIGS. 2 and 3. The construction units 28 may be referred to herein as“first” and/or “second” construction units.

FIGS. 2 and 3 are perspective views of an exemplary embodiment of aconstruction unit 28. The construction unit 28 includes a wall segment30 and a corner segment 32. The wall segment 30 and the corner segment32 are integrally formed with each other to define the“one-piece”structure of the construction unit 28. In other words, theintegral formation of the wall segment 30 and the corner segment 32provide the construction unit 28 as a single continuous structure thathas only one piece. The construction unit 28 may be fabricated using anyprocess, method, means, structure, machine, and/or the like thatprovides the construction unit 28 with the “one-piece” structuredescribed and illustrated herein, such as, but not limited to, using amolding process (e.g., injection molding and/or the like), using acasting process, using a machining and/or other cutting process, usingan extrusion process, and/or the like.

The construction unit 28 includes an internal side 34 and an oppositeexternal side 36. The construction unit 28 extends a height along thez-axis from an edge 38 to an opposite edge 40.

The wall segment 30 of the construction unit 28 extends a length from acorner end 42 to a free end 44 that is opposite the corner end 42. Inthe exemplary embodiment of the construction unit 28, the length of thewall segment 30 extends along an approximately straight path between theends 42 and 44. In other embodiments, the length of the wall segment 30extends along an angled and/or curved path between the ends 42 and 44.The wall segment 30 extends a height H along the z-axis from the edge 38to the edge 40 of the construction unit 28. As will be described below,the length of the wall segment 30 is trimmable to provide theelectronics enclosure 10 with a pre-selected x-axis or y-axis dimension(depending on whether the length of the wall segment 30 extends alongthe x-axis or the y-axis). It should be understood that for some shapes,different wall segments 30 of the same z-axis section 18 may havelengths that have different dimensional values.

The corner segment 32 extends outward from the corner end 42 of the wallsegment 30. The corner segment 32 includes a base 46 that extends fromthe wall segment 30, and a receiver socket 48 that extends outward fromthe base 46. The receiver socket 48 is configured to receive the freeend 44 of another construction unit 28 therein to connect theconstruction units 28 together, as will be described below. The receiversocket 48 has a size and shape that is configured to receive the freeend 44 of another construction unit 28 therein in a manner that enablesthe construction units 28 to be mechanically connected together, forexample as is described below with reference to FIG. 6. In the exemplaryembodiment of the construction unit 28, the receiver socket 48 has theshape of a parallelepiped. But, the receiver socket 48 may additionallyor alternatively include any other size and/or shape that enables theconstruction units 28 to be mechanically connected together.

In the exemplary embodiment of the construction unit 28, the receiversocket 48 extends at angle of approximately 90° relative to the lengthof the wall segment 30. Specifically, the wall segment 30 extends thelength along a central longitudinal axis 50 and the receiver socket 48extends a depth along a central depth axis 52. As can be seen in FIGS. 2and 3, the axes 50 and 52 extend at an approximate perpendicular angle αrelative to each other. In other embodiments, the receiver socket 48extends at different angle relative to the length of the wall segment30, as will be discussed below.

The corner segment 32 includes one or more internal mounting features 54for mounting one or more electronic and/or other devices 16 (FIGS. 6 and10) to the construction unit 28. The mounting feature 54 may be used incombination with the mounting features 54 of other construction units 28of the same z-axis section 18 to hold the electronic and/or otherdevice(s) 16 within an internal cavity 56 (FIGS. 1, 6, 9, and 10) of thez-axis section 18. The internal mounting feature 54 extends on theinternal side 34 of the construction unit 28. In the exemplaryembodiment of the construction unit 28, the internal mounting feature 54is a groove 54 a that is configured to receive a mounting bracket 58(FIGS. 6 and 10) that is either a component of, or is mechanicallyconnected to, the electronic and/or other device(s) 16. The groove 54 amay be considered a keying feature that receives a key 72 (FIGS. 6 and10) of the mounting bracket 58 therein. In the exemplary embodiment ofthe groove 54 a, the groove 54 a receives the key 72 with aninterference fit. In addition or alternatively to the groove 54 a, theinternal mounting feature 54 may include any other structure thatenables the construction unit 28 to be mechanically connected to theelectronic and/or other device(s) 16, such as, but not limited to, anopening that receives a fastener therein, a slot, a clip, a latch, aclamp, a different interference-fit member, a snap-fit member, and/orthe like. Moreover, in addition or alternatively to the internalmounting feature 54 on the corner segment 32, the construction unit 28may include one or more internal mounting features 54 positioned atanother location along the construction unit 28, for example along thewall segment 30. A common spider assembly (not shown) is optionallymounted to the mounting features 54 of corresponding (e.g., alignedalong the z-axis) corner segments 32 of different z-axis sections 18 toincrease the rigidity of an assembled electronics enclosure 10. Thespider assembly may include framework (e.g., a web of framework) thatreinforces the corner segments 32 of the z-axis sections 18.

Optionally, the corner segment 32 includes a strengthening boss 60 forincreasing the strength, rigidity, mechanical integrity, and/or the likeof the electronics enclosure 10, for example at the corners thereof. Inthe exemplary embodiment, the strengthening boss 60 is an area ofincreased thickness on the external side 36 of the construction unit 28.In addition or alternatively, the construction unit 28 may include astrengthening boss positioned at another location along the constructionunit 28. The strengthening boss 60 may have any size and/or shape, whichmay be configured to provide the electronics enclosure 10 with apredetermined strength, rigidity, mechanical integrity, and/or the like.

The construction unit 28 optionally includes one or more reinforcementribs (not shown) that extends along the wall segment 30 and/or thecorner segment 32 on the internal side 34 and/or the external side 36 ofthe construction unit 28. Such reinforcement ribs may facilitateincreasing the rigidity of the corresponding z-axis section 18 along thex-axis and y-axis dimensions of the corresponding z-axis section 18.

The construction unit 28 includes one or more stacking features 62 (bestseen in FIG. 2) that extend along the edge 40 of the construction unit28 for stacking the z-axis section 18 of the construction unit 28 onanother z-axis section 18. The construction unit 28 also includes one ormore stacking features 64 (best seen in FIG. 3) that extend along theedge 38 of the construction unit 28 for stacking another z-axis section18 on the z-axis section 18 of the construction unit 28. The stackingfeatures 62 and 64 enable z-axis sections 18 to be stacked andmechanically connected together within the stack 20 (FIGS. 1 and 10).Specifically, the stacking feature 62 of the one-piece construction 28interlocks with the stacking feature 64 of a construction unit 28 ofanother z-axis section 18 that is stacked on the z-axis section 18 ofthe construction unit 28. Similarly, the stacking feature 64 of theone-piece construction 28 interlocks with the stacking feature 62 of aconstruction unit 28 of another z-axis section 18 on which the z-axissection 18 of the construction unit 28 is stacked. The stacking features62 and 64 of the construction units 28 of two stacked z-axis sections 18thus interlock the stacked z-axis sections 18 within the stack 20.

In the exemplary embodiment of the construction unit 28, the stackingfeatures 62 and 64 are tongue and groove joints, respectively.Specifically, as respectively shown in FIGS. 2 and 3, the stackingfeature 62 is a tongue 62 a and the stacking feature 64 is a groove 64a. The tongue 62 a of the construction unit 28 interlocks with thegroove 64 a of a construction unit 28 of another z-axis section 18 suchthat the tongue 62 a nests within the groove 64 a. The groove 64 a ofthe construction unit 28 interlocks with the tongue 62 a of aconstruction unit 28 of another z-axis section 18 such that the tongue62 a nests within the groove 64 a of the other z-axis section 18. Thestacking features 62 and 64 of the construction unit 28 are not limitedto the tongue and groove joints 62 a and 64 a. Rather, in addition oralternatively to the tongue and groove joints 62 a and 64 a, thestacking features 62 and 64 may include any other structure that enablesthe construction unit 28 to be stacked on another z-axis section 18,such as, but not limited to, a lap joint, and/or the like.

Referring again to FIG. 1, the corner segment 32 includes one or moreexternal mounting features 66 for mounting one or more supportstructures to the electronics enclosure 10. The support structures thatmount to the electronics enclosure 10 facilitate supporting, mounting,compression, and/or the like of the electronics enclosure 10. Suchsupport structures may include, but are not limited to, support feetthat support the enclosure 10 on a surface, support rails (e.g., thesupport rails 373 shown in FIG. 15) that are used to securely connectthe enclosure 10 to another support structure (e.g., a wall, a floor, aceiling, a rack, a panel, a frame, an airframe, a rail, and/or thelike), and/or the like. The external mounting feature 66 extends on theexternal side 36 of the construction unit 28.

In the exemplary embodiment of the construction unit 28, the externalinternal mounting features 66 are grooves 66 a that are configured toreceive a key (not shown) of the support structure for mounting thesupport structure to the construction unit 28. In addition oralternatively to the grooves 66 a, the external mounting feature 66 mayinclude any other structure that enables the support structure to bemounted to the construction unit 28, such as, but not limited to, anopening that receives a fastener, a clip, a slot, a latch, aninterference-fit member, a snap-fit member, an angled foot receiver forentrapping a foot and/or a rail, and/or the like. Moreover, in additionor alternatively to the external mounting feature 66 on the cornersegment 32, the construction unit 28 may include one or more externalmounting features 66 positioned at another location along theconstruction unit 28, for example along the wall segment 30.

As described above, one or more of the z-axis sections 18 includes acover 26 that defines a z-axis boundary of the internal compartment 14of the electronics enclosure 10. FIG. 4 is a perspective view of anexemplary embodiment of a modular construction unit 128 of a z-axissection 18 (FIGS. 1, 5, 6, and 8-10) that includes a cover 26 (FIGS. 1and 8-10), for example the z-axis section 18 a shown in FIG. 1. Theconstruction unit 128 is substantially similar to the construction unit28 (FIGS. 1-3, 5, 6, and 10). For example, the construction unit 128includes a wall segment 30 and a corner segment 32 that are integrallyformed with each other to define the “one-piece” structure of theconstruction unit 128. The wall segments 30 include free ends 44 and thecorner segments 32 include receiver sockets 48. Moreover, and forexample, the construction unit 128 extends a height along the z-axisfrom an edge 38 to an opposite edge 40. But, the construction unit 128also includes a cover mounting feature 68 for incorporating a cover 26into the z-axis section 18 of the construction unit 128. Theconstruction units 28 may be referred to herein as “first” and/or“second” construction units.

Moreover, the construction unit 128 optionally only includes thestacking feature 62 or the stacking feature 64. For example, if thez-axis section 18 of the construction unit 128 is an end z-axis sectionthat defines one of the ends 22 or 24 of the electronics enclosure 10,the end z-axis section 18 will only need one of the stacking feature 62or the stacking feature 64 because the end z-axis section 18 is onlydirectly mechanically connected to one other z-axis section within thestack 20. In such embodiments wherein the construction unit 128 onlyincludes the stacking feature 62 or the stacking feature 64, whichstacking feature 62 or 64 the unit 128 includes will depend on which end22 or 24 of the electronics enclosure 10 is defined by the end z-axissection 18. In the exemplary embodiment of the construction unit 128,the construction unit 128 includes both the stacking features 62 and 64.

In the exemplary embodiment of the construction unit 128, the covermounting feature 68 is a slot 68 a that receives an edge 74 (FIGS. 8 and9) of the cover 26 therein to hold the cover 26 to the construction unit128, as will be described in more detail below. As shown in FIG. 4, theslot 68 a extends along the z-axis at approximately a midpoint of theheight of the construction unit 128. But, the slot 68 a may have anyother position along the height of the construction unit 128. Inaddition or alternatively to the slot 68 a, the cover mounting feature68 may include any other structure that enables the construction unit128 to hold the cover 26, such as, but not limited to, a ledge, a clip,a latch, an interference-fit member, a snap-fit member, an opening thatreceives a fastener therein, and/or the like.

FIG. 5 is an exploded perspective view of an exemplary embodiment of thez-axis section 18 c of the electronics enclosure 10. As shown in FIG. 1,the z-axis section 18 c is an interior z-axis section 18 within thestack 20 that does not include a cover 26. Referring again to FIG. 5, asdescribed above, the z-axis section 18 c is defined by a plurality ofmodular construction units 28 that connect together in the x-y plane.The construction units 28 connect together one after the other with achasing symmetry to form the z-axis section 18 c. Specifically, FIG. 5illustrates four construction units 28 that are arranged sequentiallyone after the other in a ring. The free end 44 of the wall segment 30 ofeach construction unit 28 faces the receiver socket 48 of an adjacentconstruction unit 28 in the sequence of the ring. In other words, theconstruction units 28 are arranged sequentially one after the other suchthat the receiver socket 48 of each construction unit 28 follows thefree end 44 of the previous construction unit 28 within the sequence ofthe ring, and vice versa. The arrangement of the identical constructionunits 28 in the ring with the receiver sockets 48 following the freeends 44, and vice versa, defines the chasing symmetry of theconstruction units 28.

FIG. 6 is a perspective view of the z-axis section 18 c illustrating thez-axis section 18 c in an assembled state. As shown in FIG. 6, the freeend 44 of each construction unit 28 is received within the receiversocket 48 of the corner segment 32 of the next construction unit 28 inthe sequence of the ring such that the construction units 28 aremechanically connected together at the interface between the free end 44and the receiver socket 48. The construction units 28 are thus connectedtogether one after the other with the chasing symmetry to form acontinuous ring that defines the z-axis section 18 c. Although four areshown, any number of construction units 28 may be connected together todefine the z-axis section 18 c, which as will be described below mayhave any other shape than the square shape shown herein.

Reception of the free end 44 within the receiver socket 48 mechanicallyconnects adjacent construction units 28 together. The free ends 44 areoptionally received within the receiver sockets 48 with an interferenceand/or snap fit. For example, the interference and/or snap fit may beprovided by a detent arrangement, a dimple/divot arrangement, abar/groove arrangement, another arrangement, and/or the like. Whether ornot the free ends 44 are received within the receiver sockets 48 with aninterference and/or snap fit, one or more other structures and/ormaterials is optionally used to strengthen the mechanical connection at,and/or seal, the interface between the free ends 44 and the receiversockets 48, such as, but not limited to, a weld, an adhesive, afastener, a clip, a latch, a clamp, and/or the like. In someembodiments, the adhesive is an activatable adhesive system.Specifically, in some embodiments, the receiver sockets 48 are coatedwith an activatable adhesive before being assembled with otherconstruction units 28, for example during fabrication of theconstruction unit 28. When an activatable adhesive system is used, theconstruction units 28 can be assembled dry, and later fused together asneeded by activating the adhesive. The activatable adhesive system maybe activated in any manner, such as, but not limited to, using heat,electrical current, radio waves, ultraviolet radiation, and/or the like.

As briefly described above, the length of the wall segment 30 of eachconstruction unit 28 is trimmable to provide the z-axis section 18 cwith a pre-selected x-axis or y-axis dimension (depending on whether thelength of the wall segment 30 extends along the x-axis or the y-axis).Accordingly, the x-axis and y-axis dimensions of the z-axis section 18 care scalable by trimming the wall segment 30 of each construction unit28 to a pre-selected length that provides the z-axis section 18 c with apre-selected x-axis or y-axis dimension. The construction units 28 aremodular units that can be connected together in any number to form az-axis section 18 c having any shape (with any number of sides), anyx-axis dimension, and any y-axis dimension. In other words, theconstruction units 28 provide standard (i.e., universal) building blocksthat can be connected together to build a z-axis section 18 c of anysize. The identical construction units 28 may be fabricated from thesame mold or extrusion die, which may eliminate the need to providedifferent molds and/or dies for producing differently sized and/orshaped electronics enclosures. Moreover, by reducing the number of moldsand/or dies required to produce a z-axis section 18, the identicalconstruction units 28 may enable accelerated production of differentelectronics enclosures 10 by eliminating the time it takes to fabricatethe additional molds and/or dies.

Optionally, an extension construction unit may be provided along one ormore of the sidewalls 12 of the electronics enclosure 10. Specifically,the wall segment 30 of one or more of the one-piece construction blocks28 may be effectively lengthened using a discrete extension constructionunit that is connected within the ring of the z-axis section 18 cbetween two construction units 28 that would be otherwise be adjacentwithin the ring. The extension one piece construction units aresubstantially similar to the construction units 28 except the extensionconstruction units have an angle of approximately 0° between thereceiver socket 48 and the wall segment 30 thereof such that theentirety of the length of the extension one piece construction unit isapproximately straight. The extension construction units extend themaximum x-axis and y-axis dimensions to which the z-axis section 18 c,and thus the electronics enclosure 10, is capable of being built.Moreover, the strengthening bosses 60 of corresponding extensionconstruction units of a plurality of stacked z-axis sections 18 will addrigidity and/or strength to such larger enclosures 10 by forming areinforcing rib that extends along the z-axis. The extensionconstruction units may also be used with the z-axis sections 18 a and 18b that are formed from the construction units 128.

For example, FIG. 7 is a perspective view of an exemplary embodiment ofa modular extension construction unit 628. The extension constructionunit 628 includes a receiver socket 48 and a wall segment 30. The wallsegment 30 of the extension construction unit 628 has a free end 44 thatis configured to be received within the receiver socket 48 of aconstruction unit 28 or 128. The receiver socket 48 of the extensionconstruction unit 628 is configured to receive the free end 44 of thewall segment 30 of a construction unit 28 or 128. As shown in FIG. 7,the wall segment 30 and the receiver socket 48 of the extensionconstruction unit 628 have an angle of approximately 0° relative to eachother such that the entirety of the length of the extension one piececonstruction unit 628 is approximately straight. The receiver socket 48of the construction unit 628 optionally includes one or more of theinternal mounting features 54 for mounting one or more electronic and/orother devices 16 (FIGS. 6 and 10) to the extension construction unit628. An exemplary embodiment of a mounting bracket 658 is connected tothe mounting feature 54 for supporting the electronic and/or otherdevice(s) 16. Moreover, the receiver socket 48 of the extensionconstruction unit 628 includes a strengthening boss 60 that may addrigidity and/or strength to the enclosure 10 by forming a reinforcingrib that extends along the z-axis.

Referring again to FIG. 6, the continuous ring formed by theinterconnected construction units 28 defines the internal cavity 56 ofthe z-axis section 18 c. The internal cavity 56 is bounded by theinternal sides 34 of the construction units 28. When the electronicsenclosure 10 only includes a single z-axis section 18 (e.g., includesthe z-axis section 18 c but does not include any other z-axis sections18), the internal cavity 56 defines the internal compartment 14 of theelectronics enclosure 10. When the electronics enclosure includes aplurality of z-axis sections 18 (e.g., the z-axis sections 18 a, 18 b,and 18 c) stacked together, the internal cavity 56 of each z-axissection 18 defines a corresponding portion of the internal compartment14 of the electronics enclosure 10.

The z-axis section 18 c holds one or more electronic devices 16. In theexemplary embodiment of the z-axis section 18 c, the electronic device16 is a circuit board 16 a that includes a plurality of electricalcomponents (e.g., traces, contacts, processors, integrated circuits,modules, packages, and/or the like). But, as described above, theelectronic device 16 a may be any other type of electronic device. Theelectronic device 16 a includes a plurality of mounting brackets 58 thatare mechanically connected thereto using openings 70 and fasteners (notshown) that extend within the openings 70. Alternatively, the mountingbrackets 58 are integrally formed with the electronic device 16 a or aremechanically connected to the electronic device 16 a in a differentmanner and/or using different structure than the openings 70 andfasteners.

The key 72 of each mounting bracket 58 is received within the groove 54a of a corresponding one of the construction units 28 to mechanicallyconnect the electronic device 16 a to the construction units 28 andthereby hold the electronic device 16 a within the internal cavity 56 ofthe z-axis section 18 c. The keys 72 are optionally received within thegrooves 54 a with an interference and/or snap fit to securely connectthe mounting brackets 58 to the construction units 28. Whether or notthe keys 72 are received within the grooves 54 a with an interferenceand/or snap fit, one or more other structures and/or materials isoptionally used to strengthen the mechanical connection at, and/or seal,the interface between the keys 72 and the grooves 54 a, such as, but notlimited to, a weld, an adhesive, a fastener, a clip, a latch, a clamp,and/or the like. In some embodiments, the adhesive is an activatableadhesive system.

FIG. 8 is an exploded perspective view of an exemplary embodiment of thez-axis section 18 b of the electronics enclosure 10. As shown in FIG. 1,the z-axis section 18 b is an end z-axis section 18 within the stack 20that includes the cover 26 b and defines the end 24 of the electronicsenclosure 10. The z-axis section 18 b is defined by the cover 26 b and aplurality of modular construction units 128 that connect together in thex-y plane. The identical construction units 128 connect together oneafter the other with a chasing symmetry to form the z-axis section 18 b.The cover 26 b extends between a plurality of edges 74. The constructionunits 128 include the wall segments 30 and the corner segments 32. Theconstruction units 128 also include the cover mounting features 68 forincorporating the cover 26 b into the z-axis section 18 b. Specifically,in the exemplary embodiment of the construction units 128, theconstruction units 128 include the slots 68 a.

FIG. 9 is a perspective view of the z-axis section 18 b illustrating thez-axis section 18 b in an assembled state. As shown in FIG. 9, theconstruction units 128 are connected together one after the other withthe chasing symmetry to form a continuous ring that defines the z-axissection 18 b. Specifically, the free end 44 of the wall segment 30 ofeach construction unit 128 is received within the receiver socket 48 ofthe corner segment 32 of the next construction unit 128 in the sequenceof the ring such that the construction units 128 are mechanicallyconnected together at the interfaces between the free end 44 and thereceiver socket 48. The continuous ring formed by the interconnectedconstruction units 128 defines the internal cavity 56 of the z-axissection 18 b. Although four are shown, any number of construction units128 may be connected together to define the z-axis section 18 b, whichas will be described below may have any other shape than the squareshape shown herein.

The free ends 44 of the construction units 128 are optionally receivedwithin the receiver sockets 48 with an interference and/or snap fit.Whether or not the free ends 44 are received within the receiver sockets48 with an interference and/or snap fit, one or more other structuresand/or materials is optionally used to strengthen the mechanicalconnection at, and/or seal, the interface between the free ends 44 andthe receiver sockets 48, such as, but not limited to, a weld, anadhesive, a fastener, a clip, a latch, a clamp, and/or the like. In someembodiments, the adhesive is an activatable adhesive system. When anactivatable adhesive system is used, the construction units 128 can beassembled dry, and later fused together as needed by activating theadhesive.

As is also shown in FIG. 9, the cover 26 b is positioned within theinternal cavity 56 of the z-axis section 18 b. Each edge 74 of the cover26 b is received within the slot 68 a of the corresponding constructionunit 128 such that the cover 26 b is mechanically connected to theconstruction units 128. The cover 26 b is thus held within the internalcavity 56 of the z-axis section 18 b. The edges 74 of the cover 26 b areoptionally received within the corresponding slots 68 a with aninterference and/or snap fit. Whether or not the edges 74 are receivedwithin the slots 68 a with an interference and/or snap fit, one or moreother structures and/or materials is optionally used to strengthen themechanical connection at, and/or seal, the interface between the edges74 and the slots 68 a, such as, but not limited to, a weld, an adhesive,a fastener, a clip, a latch, a clamp, and/or the like. In someembodiments, the adhesive is an activatable adhesive system.

In the exemplary embodiment of the z-axis section 18 b, the cover 26 bis held along the z-axis at approximately a midpoint of the height ofthe z-axis section 18 b. But, the cover 26 b may be held at any otherposition along the height of the z-axis section 18 b.

The construction units 128 of the z-axis section 18 b include the innertongue 62 a of the stacking feature 62 for interconnection with thegroove 64 a (FIGS. 2, 3, and 10) of the construction units 28 (FIGS.1-3, 5, 6 and 10) of the z-axis section 18 c (FIGS. 1, 5, 6, and 10).

The length of the wall segment 30 of each construction unit 128, as wellas the x-axis and y-axis dimensions of the cover 26 b, are trimmable toprovide the z-axis section 18 c with pre-selected x-axis and y-axisdimensions. Accordingly, the x-axis and y-axis dimensions of the z-axissection 18 b are scalable by trimming the wall segment 30 of eachconstruction unit 128 to a pre-selected length, and by trimming thecover 26 b to pre-selected x-axis and y-axis dimensions, that providethe z-axis section 18 b with pre-selected x-axis and y-axis dimensions.The construction units 128 are modular units that can be connectedtogether in any number to form a z-axis section 18 b having any shape(with any number of sides), any x-axis dimension, and any y-axisdimension. In other words, the construction units 128 provide standard(i.e., universal) building blocks that can be connected together tobuild a z-axis section 18 b of any size. The identical constructionunits 128 may be fabricated from the same mold or extrusion die, whichmay eliminate the need to provide different molds and/or dies forproducing differently sized and/or shaped electronics enclosures.Moreover, by reducing the number of molds and/or dies required toproduce a z-axis section 18, the identical construction units 128 mayenable accelerated production of different electronics enclosures 10 byeliminating the time it takes to fabricate the additional molds and/ordies.

FIG. 10 is an exploded perspective view of the electronics enclosure 10.Referring now to FIGS. 1 and 10, the electronics enclosure 10 is formedby one or more z-axis sections 18. When the electronics enclosure 10includes more than one z-axis section 18, the electronics enclosure 10is formed by stacking two or more z-axis sections 18 on top of eachother along the z-axis. The internal cavity 56 of each z-axis section 18defines a corresponding portion of the internal compartment 14 of theelectronics enclosure 10 such that the internal compartment 14 includes(i.e., is defined by) the internal cavities 56 of each z-axis section 18within the stack 20.

The z-axis dimension of the electronics enclosure 10 may be pre-selectedby selecting the number of z-axis sections 18 that make up the stack 20.In the exemplary embodiment of the electronics enclosure 10, the stack20 of z-axis sections 18 of the electronics enclosure 10 includes thethree z-axis sections 18 a, 18 b, and 18 c. But, any number of z-axissections 18 may be stacked to build the electronics enclosure 10.Accordingly, the z-axis dimension of the electronics enclosure 10 isscalable by selecting the number of z-axis sections 18 that are stackedon top of each other. In other words, the z-axis sections 18 are modularsections that provide standard (i.e., universal) building blocks thatcan be stacked together in any number to build an electronics enclosure10 having any z-axis dimension. Optionally, one or more z-axis sections18 includes a different size and/or shape than one or more other z-axissections 18 to build and enclosure 10 that has a non-uniform size and/orshape along the z-axis (e.g., a 4×4×4 cube attached to a 3×3×3 cube).

Referring now solely to FIG. 10, within the stack 20, the tongues 62 aof the construction units 128 of the z-axis section 18 b are interlockedwith the grooves 64 a of the construction units 28 of the z-axis section18 c to mechanically connect and thereby interlock the z-axis sections18 b and 18 c. Similarly, the tongues 62 a of the construction units 28of the z-axis section 18 c are interlocked with the grooves 64 a of theconstruction units 28 of the z-axis section 18 a to mechanically connectand thereby interlock the z-axis sections 18 b and 18 a. The tongues 62a and grooves 64 a of adjacent z-axis sections 18 within the stack 20optionally interlock with an interference and/or snap fit. For example,the interference and/or snap fit may be provided by a detentarrangement, a dimple/divot arrangement, a bar/groove arrangement,another arrangement, and/or the like. Whether or not the tongues 62 aand the grooves 64 a interlock with an interference and/or snap fit, oneor more other structures and/or materials is optionally used tostrengthen the mechanical connection at, and/or seal, the interlockbetween corresponding tongues 62 a and grooves 64 a, such as, but notlimited to, a weld, an adhesive, a fastener, a clip, a latch, a clamp,and/or the like. In some embodiments, the adhesive is an activatableadhesive system. Specifically, in some embodiments, the tongues 62 a andgrooves 64 a of a z-axis section 18 are coated with an activatableadhesive before being stacked with other z-axis sections 18, for exampleduring fabrication of the construction units 28 and/or 128. When anactivatable adhesive system is used, the z-axis sections 18 of anelectronics enclosure can be stacked dry, and later fused together asneeded by activating the adhesive.

Optionally, an electromagnetic interference (EMI) gasket (not shown) isincorporated into the interlocking stacking features 62 and 64 of thez-axis sections 18 to facilitate containing EMI within the internalcompartment of the electronics enclosure 10 and/or to facilitateshielding the electronic device(s) 16 within the internal compartment 14from EMI originating outside of the electronics enclosure 10. In suchembodiments wherein an EMI gasket is incorporated into the interlockingstacking features 62 and 64, any adhesive used with the mechanicalconnection between the construction units 28 or 128 of a z-axis section18 may be provided as electrically conductive to form an integral EMIshield with the EMI gasket.

In the exemplary embodiment of the electronics enclosure 10, the stack20 consists of a single interior z-axis section 18 c and two end z-axissections 18 a and 18 b that define the respective ends 22 and 24 of theelectronics enclosure 10. But, the stack 20 of z-axis sections 18 of theelectronics enclosure 10 may include any number of interior z-axissections 18 that are positioned within the stack 20 between the endz-axis sections 18 that define the opposite ends 22 and 24 of the stack20. Moreover, in the exemplary embodiment of the electronics enclosure10, the interior z-axis section 18 c holds the electronic device 16 a,while the end z-axis sections 18 a and 18 b include the respectivecovers 26 a and 26 b that provide z-axis boundaries at the ends 22 and24, respectively, of the electronics enclosure 10. In other words, theexemplary embodiment of the electronics enclosure 10 includes two z-axissections 18 a and 18 b that include covers 26 and a single z-axissection 18 c that holds one or more electronic devices 16. But, anyother number of z-axis sections 18 of the electronics enclosure 10 mayhold one or more electronic devices 16, and any other number of z-axissections 18 of the electronics enclosure 10 may include a cover 26. Insome embodiments, a particular electronic device 16 is held by twoadjacent z-axis section 18 within the stack 20. For example, the keys 72of the mounting brackets 58 of the particular electronic device 16 maybe received within the grooves 54 a of two adjacent z-axis sections 18within the stack 20.

The z-axis sections 18 that hold electronic devices 16 are not limitedto being interior z-axis sections 18 within the stack 20. Rather, az-axis section 18 that holds one or more electronic devices 16 may be anend z-axis section 18 that defines the end 22 or 24 of the electronicsenclosure 10. Moreover, the z-axis sections 18 that include covers 26are not limited to being an end z-axis sections 18 that provides az-axis boundary of the internal compartment 14 at the end 22 or 24 ofthe electronics enclosure 10. Rather, the stack 20 of z-axis sections 18of the electronics enclosure 10 may include an interior z-axis section18 that includes a cover 26. In such embodiments, the cover 26 of theinterior z-axis section 18 may provide a divider within the internalcompartment 14 that separates the internal cavities 56 of other z-axissections 18 within the stack 20. In such embodiments wherein the stack20 includes an interior z-axis section 18 having a cover 26, the cover26 is optionally electrically conductive and supplied with electricalcurrent such that the cover 26 provides a radio frequency (RF) shield(e.g., an EMI barrier) between the internal cavities 56 of adjacentz-axis sections 18 within the stack 20. For example, the RF shield mayextend between electrical devices 16 that are held by different z-axissections 18 within the stack 20. In such embodiments wherein a cover 26provides an RF shield, the cover 26 may include any type of feed-through(e.g., an opening, a conduit, a fixture, and/or the like), connector,and/or the like for providing, through the cover 26, an electricalconnection between the z-axis sections 18 that are isolated by the cover26.

In the exemplary embodiment of the electronics enclosure 10, each of thez-axis sections 18 either includes a cover 26 or holds an electronicdevice 16. But, in other embodiments, one or more z-axis sections 18 ofthe electronics enclosure does not include a cover 26 and does not holdany electronic devices 16. For example, the internal cavity 56 of one ormore z-axis sections 18 within the stack 20 may provide an open space(i.e., volume) that extends between the internal cavities 56, and thusthe covers 26 and/or electronic devices 16, of other z-axis sections 18within the stack 20. Moreover, and for example, the internal cavity 56of one or more end z-axis sections 18 may not include a cover 26 or holdan electronic device 16, such that the internal compartment 14 of theelectronics enclosure is open at the end 22 and/or 24. Further, theinternal cavity 56 of one or more end z-axis sections 18 may hold one ormore electronic devices 16 but no cover 26 such that the end 22 and/or24 of the electronics enclosure 10 is defined by a z-axis section 18that holds an electronic device 16 instead of a z-axis section 18 thatincludes a cover 26.

As discussed above, the stack 20 of the electronics enclosure 10 includeany number of z-axis sections 18. Each z-axis section 18 may hold anynumber of electronic devices 16 and/or any number of covers 26.Moreover, the electronics enclosure 10 may include any number ofelectronic devices 16 overall and any number of covers 26 overall.

Referring again to FIG. 1, the z-axis sections 18 may be held (e.g.,compressed) together in the stack 20 using any structure, means, and/orthe like, such as, but not limited to, using a threaded fastener (e.g.,a threaded rod), a strap, a clip, a band, a tie-down, a support rail, asupport foot, a threaded rod, any of the connections betweencorresponding stacking features 62 and 64 described herein (e.g.,snap-fits, interference fits, adhesive, and/or the like), and/or thelike. For example, in some embodiments, a threaded rod (not shown)extends through openings (not shown) of the z-axis sections 18 (e.g., atone or more corners 76 of the enclosure 10, through one or more cornersegments 32, through the electronic devices 16 of the z-axis sections18, through the covers 26, and/or the like) to compress the z-axissections 18 together and thereby hold the z-axis sections 18 together inthe stack 20 (e.g., using a threaded nut and/or threads of the openingsof the z-axis sections 18 to tighten the threaded rod). Another exampleincludes using a support rail (e.g., the support rails 373 shown in FIG.15) and/or support foot (e.g., the feet 469 shown in FIG. 16) thatextends along the z-axis of the enclosure 10 and mounts to the z-axissections 18 to hold the z-axis sections 18 together in the stack 20.

One or more of the sidewalls 12 of the electronics enclosure 10optionally includes one or more ports (not shown) that extend throughthe corresponding sidewall 12 into the internal compartment 14. One ormore ports may be used for thermal management, for example to vent heatfrom the internal compartment 14. In addition or alternatively, one ormore ports may be used to pass one or more electrical conductors (notshown) through the corresponding sidewall 12, one or more ports may beused to mount an electrical and/or optical connector (not shown) to thecorresponding sidewall 12, and/or one or more ports may be used toenable one or more other components to be mounted to and/or pass throughthe corresponding sidewall 12. Each port may extend through only onez-axis section 18 (e.g., through the wall segment 30 of a singlecorresponding construction unit 28 or 128 of a single z-axis section18), or may be shared by two z-axis sections 18 (e.g., extending throughinterlocked wall segments 30 of adjacent z-axis sections 18 within thestack 20 such that the port bridges the adjacent z-axis sections 18).Providing a port that is shared by adjacent z-axis sections 18 mayfacilitate easing removal of the corresponding component that is mountedto and/or passes through the corresponding sidewall 12 for rework. Eachport may be provided with a seal (not shown) and/or a sealing surface toseal the corresponding component that is mounted to and/or passesthrough the corresponding sidewall 12. When a port is shared by adjacentz-axis sections 18, the seal and/or the sealing surfaces of the adjacentz-axis sections 18 define a shared seal that is shared between theadjacent z-axis sections 18. In addition or alternatively to a seal, areinforcing boss may be used to support the corresponding component thatis mounted to and/or passes through the corresponding sidewall 12.

Each port may be formed during fabrication of the correspondingconstruction unit(s) 28 and/or 128, after fabrication of thecorresponding construction unit(s) 28 and/or 128 but before thecorresponding z-axis section(s) 18 is assembled, after the correspondingz-axis section(s) 18 has been assembled but before any of the z-axissections 18 have been stacked together, after only some of the z-axissections 18 have stacked together, or after all of the z-axis sections18 have been stacked together to define the electronics enclosure 10.When formed after fabrication of the corresponding construction unit(s)28 and/or 128, each port may be formed using any suitable cuttingprocess, such as, but not limited to, drilling, machining, boring, usingheat, using a laser, water cutting, and/or the like. In someembodiments, one or more of the ports is provided during fabrication ofthe corresponding construction unit(s) 28 and/or 128 as a cutout and/orknockout that can be cut out and/or knocked out, respectively, by aperson and/or machine that is building the electronics enclosure 10,which may reduce the number of cutting operations performed by theperson and/or machine building the electronics enclosure 10.

In the exemplary embodiment of the electronics enclosure 10, theelectronics enclosure 10 has the overall shape of parallelepiped. Theparallelepiped shape of the electronics enclosure 10 is defined by thesquare shapes of the z-axis sections 18. But, the overall shape of theelectronics enclosure 10 is not limited to a parallelepiped shape, norare the z-axis sections 18 limited to a square shape. Rather, the z-axissections 18 may have any other shape in the x-y plane, such as, but notlimited to, a circular shape, a different rectangular shape (e.g., anon-square shape), a triangular shape, a hexagonal shape, a curvedshape, an oval shape, a multilateral shape, a parabola shape, a shapehaving more than four sides, an irregular shape, a non-uniform shape, astepped shape, a non-symmetrical shape, and/or the like. Moreover, theelectronics enclosure 10 may have any other overall shape, such as, butnot limited to, a cylindrical shape (e.g., a circular cross-sectionalshape in the x-y plane), a different parallelepiped shape, a triangularcross-sectional shape in the x-y plane, a curved cross-sectional shapein the x-y plane, an oval cross-sectional shape in the x-y plane, ahexagonal cross-sectional shape in the x-y plane, a multilateral shape,a parabola cross-sectional shape in the x-y plane, a shape having morethan four sides, an irregular shape, a stepped shape, a non-uniformshape, a non-symmetrical shape, and/or the like.

For example, in the exemplary embodiment of the electronics enclosure10, the z-axis sections 18 are defined by four construction units 28 or128 that connect together in the x-y plane. The receiver sockets 48 ofthe construction units 28 or 128 of the z-axis sections 18 extend atangles of approximately 90° relative to the lengths of the wall segments30. The four construction units 28 or 128 and the angles ofapproximately 90° provides each z-axis section 18 with four sides (i.e.,a four-sided shape). But, the receiver socket 48 of each constructionunit 28 and 128 may be angled at any angle relative to the length of thewall segment 30 of the construction unit 28 or 128, and each z-axissection 18 may include any number of construction units 28 or 128, thatprovides the z-axis section 18 with any shape having any number ofsides. For example, the receiver socket 48 of each construction unit 28and 128 may extend at an angle of between approximately 0° andapproximately 180° relative to the length of the wall segment 30 of theconstruction unit 28 or 128. Moreover, and for example, in embodimentswherein the z-axis sections 18 have the shape of an equilateral trianglein the x-y plane, the receiver sockets 48 are angled at approximately60° relative to the length of the corresponding wall segment 30. Anotherexample has receiver sockets 48 that are angled at approximately 120°relative to the length of the corresponding wall segment 30, for examplein embodiments wherein the z-axis sections 18 have a hexagonal shape inthe x-y plane. In some embodiments, construction units 28 and/or 128that have different angles between the receiver socket 48 and the wallsegment 30 thereof may be fabricated using the same mold and/orextrusion die by providing the mold and/or extrusion die with an insertthat can be rotated, or otherwise moved, between a plurality ofdifferent positions that give different angles between the receiversocket 48 and the wall segment 30.

As discussed above, the construction units 28 may be fabricated from thesame mold or extrusion die, which may eliminate the need to providedifferent molds and/or dies for producing differently sized and/orshaped electronics enclosures. Moreover, by reducing the number of moldsand/or dies required to produce a z-axis section 18, the identicalconstruction units 28 may enable accelerated production of differentelectronics enclosures 10 by eliminating the time it takes to fabricatethe additional molds and/or dies.

In embodiments wherein the z-axis sections 18 include a curved shape inthe x-y plane, the lengths of the wall segments 30 and/or the cornersegments 32 of at least some of the construction units 28 and 128 extendalong an at least partially curved path. Any curved portions of theconstruction units 28 and 128 may have any radius, which may or may nothave a continuous value (e.g., circular z-axis sections 18 will have acontinuous radius while oval-shaped z-axis sections 18 will have avariable radius). In embodiments wherein the z-axis sections 18 includea curved shape in the x-y plane, any construction units 28 and 128having a wall segment 30 and/or a corner segment 32 that follows an atleast partially curved path may be fabricated with the curved path ormay be fabricated with an approximately straight path and thereafterbent to define the curved path. Moreover, the wall segment 30 and/orcorner segment 32 may be bent after fabrication to change the radius ofa curve formed during fabrication of the construction unit 28 or 128.For example, the construction unit 28 or 128 may be heated to enable thebend.

In the exemplary embodiment of the electronics enclosure 10, the z-axissections 18 include convex exterior corners 76, as can be seen inFIG. 1. But, in some other embodiments, the z-axis sections 18 have ashape that includes both one or more convex exterior corners and one ormore concave exterior corners, which may provide the z-axis section 18with a relatively complex shape, such as, but not limited to, anirregular shape, a stepped shape, a non-symmetrical shape, a symmetricalshape, and/or the like. For example, the orientation of at least oneconstruction unit 28 or 128 of a z-axis section 18 may be reversedrelative to one or more other construction units 28 or 128 of the z-axissection 18 such that the internal side 34 faces outward away from theinternal cavity 56 of the z-axis section 18 instead of inward toward theinternal cavity 56. In other words, the internal side 34 of such asreversed orientation construction unit 28 or 128 will define an externalside of the enclosure 10 and the external side 36 of such as reversedorientation construction unit 28 or 128 will define an internal side ofthe enclosure 10. Accordingly, a relatively complex shaped electronicsenclosure can be built by combining concave exterior corners and convexexterior corners in any combination and number.

The construction units 28 and 128 may each be fabricated from anymaterials. In some embodiments, at least some of the construction units28 and at least some of the construction units 128 are fabricated fromone or more polymers. Moreover, at least some of the covers 26 arefabricated from one or more polymers in some embodiments. Fabricating atleast some of the construction units 28 and 128 and/or at least some ofthe covers 26 from one or more polymers may reduce a weight of theelectronics enclosure 10, for example as compared to at least some knownelectronics enclosures that are fabricated from other materials (e.g.,metals and/or the like). The polymer(s) used to fabricate theconstruction units 28 and 128 and/or the covers 26 may be selected basedon the weight thereof to provide the electronics enclosure with apredetermined weight and/or a predetermined weight savings.

Examples of polymers that may be used to fabricate the constructionunits 28 and 128 and/or the covers 26 include, but are not limited to, aplastic, a thermoplastic, a foam, an expanded material, polyimide,polyamide, polyester, polyphenylene sulfide (PPS), a natural polymericmaterial, natural rubber, cellulose, a synthetic polymer, syntheticrubber, phenol formaldehyde resin, neoprene, nylon, polyvinyl chloride(PVC), polystyrene, polyethylene, polypropylene, polyacrylonitrile,polyvinyl butyral (PVB), silicone, a shape memory polymer, a liquidcrystal polymer (LCP), polyethersulfone (PES), and/or the like. Examplesof plastics that the construction units 28 and 128 and/or the covers 26may be fabricated from include, but are not limited to, a thermoplastic,a thermosetting polymer, an acrylic, a polyester, a silicone, apolyurethane (PU), a halogenated plastic, a condensation plastic, apolyaddition plastic, a cross-linked plastic, a polyethylene (PE),low-density PE (LDPE), high-density PE, a polypropylene (PP), apolyamide (i.e., nylon), a polystyrene (PS), high impact PS, polyvinylchloride (PVC), polytetrafluoroethylene (PTFE), polyvinylidene chloride(PVDC), polyethylene terephthalate (PET), acrylonitrile butadienestyrene (ABS), PE/ABS, polycarbonate (PC), PC/ABS, polymethylmethacrylate (PMMA), urea-formaldehyde (UF), melamine formaldehyde (MF),a plastarch material, a phenolic (PF; also referred to as phenolformaldehydes), polyetheretherketone (PEEK), polyetherimide (PEI),polylactic acid (PLA), an elastomeric plastic, a synthetic plastic, anatural plastic, a bioplastic, a biodegradable plastic, asemi-crystalline plastic, a semi-amorphous plastic, a completelyamorphous plastic, a natural rubber, a synthetic rubber, and/or thelike.

In some embodiments, when a construction unit 28 or 128 is fabricatedfrom one or more polymers, a majority, at least 90%, or an approximateentirety of the construction unit is fabricated from the polymer(s).Moreover, in some embodiments, when a cover 26 is fabricated from one ormore polymers, a majority, at least 90%, or an approximate entirety ofthe cover 26 is fabricated from the polymer(s). One example offabricating less than an approximate entirety of a construction unit 28or 128 from one or more polymers includes adding one or more fillerand/or reinforcement materials to the polymer(s) used to fabricate theconstruction unit 28 or 128. The filler and/or reinforcement materialsmay modify the chemical, mechanical, thermal, and/or electricalproperties of the polymer(s) used to fabricate the construction unit 28or 128. In embodiments wherein one or more polymers is used to fabricatea construction unit 28 or 128 and one or more filler and/orreinforcement materials is added to the polymer(s), the constructionunit 28 or 128 may consist of any amount of the polymer(s), such as, butnot limited to, at least approximately 50% of the construction unit 28or 128 may consist of the polymer(s). Another example of fabricatingless than an approximate entirety of a construction unit 28 or 128includes providing the construction unit with a base material(s) that iscoated (e.g., plated) with one or more different materials (whether ornot the base material(s) includes one or more polymers, whether or notthe coating includes one or more polymers, and/or whether or not one ormore filler and/or reinforcement materials is added to the polymer(s)).In some embodiments, a construction unit 28 or 128 includes a body thatis fabricated from one or more polymers and includes a hollow interiorspace that is filled with one or more polymer(s) and/or one or moreother substances, such as, but not limited to, air, another gas, avacuum, and/or the like (whether or not one or more filler and/orreinforcement materials is added to the polymer(s)). In suchembodiments, a majority, at least 90%, or an approximate entirety of thebody of the construction unit 28 or 128 may be fabricated from thepolymer(s). Moreover, in such embodiments, the body of the constructionunit 28 or 128 may have any thickness and may be filled with any amountof the polymer(s) and/or the other substance(s). Less than anapproximate entirety of a cover 26 can be fabricated from the polymer(s)in a substantially similar fashion.

Optionally, two or more of the construction units 28 and/or 128 arefabricated from different materials to provide the construction units 28and/or 128 with different physical properties, such as, but not limitedto, thermal conductivity, electrically conductivity, opticaltransparency, electrical transparency, and/or the like. For example, oneor more of the construction units 28 and/or 128 may be fabricated from amaterial (e.g., aluminum, copper, gold, silver, iron, steel, anothermetal, and/or the like) that is thermally conductive (e.g., a thermalconductivity greater than approximately 20 Watts per meter-degree K(W/m° K) such that the construction unit(s) is thermally conductive. Insome embodiments, the material selected to provide one or moreconstruction units 28 and/or 128 as thermally conductive has a thermalconductivity of greater than approximately 20 W/m° K, at leastapproximately 100 W/m° K, between approximately 100 W/m° K andapproximately 400 W/m° K, or greater than approximately 400 W/m° K.Providing one or more construction units 28 and/or 128 that is thermallyconductive enables the electronics enclosure 10 to provide thermalmanagement to the electronic device 16 that are enclosed within theelectronics enclosure 10. For example, one or more thermally conductiveconstruction units 28 and/or 128 may be configured to act as a heat sinkfor dissipating heat from the electronic device(s) 16 enclosed withinthe electronics enclosure 10. Moreover, and for example, a heat sink(not shown) may be mounted to one or more thermally conductiveconstruction units 28 and/or 128 such that the unit(s) 28 and/or 128provide an intermediate structure that transfers heat from theelectronic device(s) to the heat sink. In addition or alternatively toone or more of the construction units 28 and/or 128, one or more covers26 may be fabricated from a material that is thermally conductive suchthat the cover(s) 26 is thermally conductive.

Another example of providing two or more of the construction units 28and/or 128 with different physical properties includes fabricating oneor more of the construction units 28 and/or 128 from a material (e.g.,aluminum, copper, gold, silver, iron, steel, another metal, and/or thelike) that is electrically conductive such that the construction unit(s)is configured to conduct electrical energy. Providing one or moreconstruction units 28 and/or 128 that is electrically conductive enablesthe electronics enclosure 10 to provide electrical functions and/orelectrical pathways to and from the electronic device(s) 16. Forexample, one or more electrically conductive construction units 28and/or 128 may provide an electrical pathway to and from an electronicdevice 16 for supplying electrical power to the electronic device 16and/or for receiving electrical power from the electronic device 16.Moreover, and for example, one or more electrically conductiveconstruction units 28 and/or 128 may provide a pathway for connectingone or more electronic devices 16 to an electrical ground. Examples ofone or more electrically conductive construction units 28 and/or 128that provide electrical functions include, but are not limited to,functioning as an antenna and/or the like. In addition or alternativelyto one or more of the construction units 28 and/or 128, one or morecovers 26 may be fabricated from a material that is electricallyconductive such that the cover(s) 26 is configured to conduct electricalenergy.

In some embodiments, one or more of the construction units 28 and/or 128is fabricated such that the construction unit 28 or 128 is opticallytransparent and/or electrically transparent. For example, an opticallytransparent construction unit 28 or 128 may be provided to enable one ormore indicators (not shown; e.g., light emitting diodes (LEDs) and/orother lights, video displays, and/or the like) within the internalcompartment 14 of the electronics enclosure 10 to be viewable fromoutside the internal compartment 14 (i.e., through the sidewalls 12and/or other portions of the electronics enclosure 10). Another exampleof using an optically transparent construction unit 28 or 128 includesusing the optical transparency to enable an infrared communications link(not shown) contained within the internal compartment 14 to send andreceive infrared signals through the optically transparent constructionunit 28 or 128. One example of using an electrically transparentconstruction unit 28 or 128 includes using the electrical transparencyto enable an RF antenna (not shown) contained within the internalcompartment 14 to send and receive RF signals through the electricallytransparent construction unit 28 or 128. In addition or alternatively toone or more of the construction units 28 and/or 128, one or more covers26 may be configured to be optically and/or electrically transparent.

Any number of the construction units 28 and/or 128 may be thermallyconductive, electrically conductive, optically transparent, and/orelectrically transparent. In some embodiments, a majority of theconstruction units 28 and 128 are fabricated from the polymer(s). Insuch embodiments, because only some of the construction units 28 and/or128 are fabricated from materials (e.g., the metals described above)that are heavier than the polymer(s) used to fabricate the majority ofthe construction units 28 and 128, the electronics enclosure 10 maystill have a reduced weight as compared to at least some knownelectronics enclosures. The number of construction units 28 and/or 128that are fabricated from the heavier materials, as well as theparticular polymeric and heavier materials used, may be selected toprovide the electronics enclosure 10 with a predetermined weight and/ora predetermined weight savings.

FIG. 11 is a perspective view of a portion of another exemplaryembodiment of a z-axis section 218. FIG. 12 is an exploded perspectiveview of the z-axis section 218. In the exemplary embodiment, the z-axissection 218 is an interior z-axis section 218 that does not include acover (not shown), but may hold an electronic device 16. Alternatively,the z-axis section 218 includes a cover. The z-axis section 218 isdefined by a plurality of modular corner segments 232 and a plurality ofmodular wall segments 230 that connect together in the x-y plane todefine an internal cavity 256 thereof. The corner segments 232 and thewall segments 230 connect together in an alternating arrangement to formthe z-axis section 218. The z-axis section 218 can then be used alone orarranged within a stack with other z-axis sections 218 to build anelectronics enclosure (not shown), wherein the internal cavity 256 ofthe z-axis section 218 defines at least a portion of an internalcompartment (not shown) of the electronics enclosure. The internalcompartment of the electronics enclosure at least partially formed bythe z-axis section 218 is configured to receive an electronic device 16(not shown with respect to the z-axis section 218). The z-axis section218 may be referred to herein as a “first”, a “second”, and/or a “third”z-axis section. Moreover, the z-axis section 218 may be referred toherein as an “additional” z-axis section.

Each wall segment 230 extends a length between opposite free ends 244.Only one free end 244 of each wall segment 230 is visible in FIGS. 11and 12. Each corner segment 232 includes opposite receiver sockets 248that are each configured to receive a corresponding free end 244 of acorresponding wall segment 230 therein in a substantially similar mannerto that described above with respect to the construction units 28 (FIGS.1-3, 5, 6 and 10) and 128 (FIGS. 1, 4, and 8-10). In the exemplaryembodiment of the z-axis section 218, the receiver sockets 248 of eachcorner segment 232 extend at an angle of approximately 90° relative toeach other and the z-axis section 218 has a four-sided shape. But, thereceiver sockets 248 of each corner segment 232 may be angled at anyangle relative to each other to provide the z-axis section 218 with anyshape having any number of sides. For example, the receiver sockets 248of each corner segment 232 may extend at an angle of betweenapproximately 0° and approximately 180° relative to each other. Eachwall segment 230 may be referred to herein as a “first” and/or a“second” wall segment. Each corner segment 232 may be referred to hereinas a “first” and/or a “second” corner segment. Each receiver socket 248may be referred to herein as a “first” and/or a “second” receiversocket.

The lengths of the wall segments 230 are trimmable to provide the z-axissection 218 with pre-selected x-axis and y-axis dimensions. Accordingly,the x-axis and y-axis dimensions of the z-axis section 218 are scalableby trimming the wall segments 230 to a pre-selected length that providesthe z-axis section 218 with a pre-selected x-axis or y-axis dimension.The corner segments 232 and the wall segments 230 are modular units thatcan be connected together in any number to form a z-axis section 218having any shape (with any number of sides), any x-axis dimension, andany y-axis dimension. In other words, the corner segments 232 and thewall segments 230 provide standard (i.e., universal) building blocksthat can be connected together to build a z-axis section 218 of anysize. The identical corner segments 232 may be fabricated from the samemold or extrusion die, which may eliminate the need to provide differentmolds and/or dies for producing differently sized and/or shapedelectronics enclosures. Similarly, the identical wall segments 230 maybe fabricated from the same mold or extrusion die, which may eliminatethe need to provide different molds and/or dies for producingdifferently sized and/or shaped electronics enclosures. Moreover, byreducing the number of molds and/or dies required to produce a z-axissection 218, production of different electronics enclosures may beaccelerated by eliminating the time it takes to fabricate the additionalmolds and/or dies.

The corner segments 232 and the wall segments 230 may each be fabricatedfrom any materials. In some embodiments, at least some of the cornersegments 232 and at least some of the wall segments 230 are fabricatedfrom one or more polymers. Fabricating at least some of the cornersegments 232 and/or at least some of the wall segments 230 from one ormore polymers may reduce a weight of the electronics enclosure, forexample as compared to at least some known electronics enclosures thatare fabricated from other materials (e.g., metals and/or the like). Thepolymer(s) used to fabricate the corner segments 232 and the wallsegments 230 may be selected based on the weight thereof to provide theelectronics enclosure with a predetermined weight and/or a predeterminedweight savings. In some embodiments, a majority of the corner segments232 and/or a majority of the wall segments 230 of the z-axis section 218and/or of an electronics enclosure that includes the z-axis section 218are fabricated from the polymer(s).

In some embodiments, when a corner segment 232 is fabricated from one ormore polymers, a majority, at least 90%, or an approximate entirety ofthe corner segment 232 is fabricated from the polymer(s). Moreover, insome embodiments, when a wall segment 230 is fabricated from one or morepolymers, a majority, at least 90%, or an approximate entirety of thewall segment 230 is fabricated from the polymer(s). Optionally, wallsegments 230 and/or corner segments 232 are fabricated from differentmaterials to provide different physical properties, such as, but notlimited to, thermal conductivity, electrically conductivity, opticaltransparency, electrical transparency, and/or the like.

The wall segments 230 and/or the corner segments 232 includes one ormore stacking features 262 (best seen in FIG. 11) for stacking thez-axis section 218 on another z-axis section 218. The wall segments 230and/or the corner segments 232 also include one or more stackingfeatures 264 (best seen in FIG. 12) for stacking another z-axis section218 on the z-axis section 218. The stacking features 262 and 264 enablez-axis sections 218 to be stacked and mechanically connected togetherwithin the stack. Specifically, the stacking features 262 and 264 ofadjacent z-axis sections 218 within the stack interlock with each other.In the exemplary embodiment of z-axis section 218, the stacking features264 and 262 are tongue and groove joints, respectively. But, in additionor alternatively to the tongue and groove joints, the stacking features262 and 264 may include any other structure that enables z-axis sections218 to be stacked, such as, but not limited to, a lap joint, and/or thelike.

Referring now solely to FIG. 12, the corner segments 232 include one ormore internal mounting features 254 for mounting one or more electronicdevices 16 (FIGS. 6 and 10) thereto. The mounting feature 254 may beused in combination with the mounting features 254 of other cornersegments 232 of the same z-axis section 218 to hold the electronicdevice(s) 16 within the internal cavity 256 of the z-axis section 218.The internal mounting feature 54 extends on the internal side 34 of theconstruction unit 28. In the exemplary embodiment of the constructionunit 28, the internal mounting feature 54 is an opening 254 a thatreceives a fastener therein. But, in addition or alternatively to theopening 254 a, the internal mounting feature 254 may include any otherstructure that enables the corner segment 232 to be mechanicallyconnected to the electronic device 16, such as, but not limited to, agroove, keying feature, a slot, a clip, a latch, a clamp, a differentinterference-fit member, a snap-fit member, and/or the like. Moreover,in addition or alternatively to the internal mounting feature 254 on thecorner segment 232, one or more wall segments 230 may include one ormore internal mounting features 254. A common spider assembly (notshown) is optionally provided to increase the rigidity of an electronicsenclosure that includes the z-axis section 218. The spider assembly mayinclude framework (e.g., a web of framework) that reinforces the cornersegments 32 of the z-axis sections 18.

FIG. 13 is a perspective view of a portion of the z-axis section 218illustrating an exemplary embodiment of an external mounting feature 266of the z-axis section 218. The external mounting feature 266 enables themounting of one or more support structures to the electronics enclosureof the z-axis section 218, for example to facilitate supporting,mounting, compression, and/or the like of the electronics enclosure. Inthe exemplary embodiment of the z-axis section 218, the externalmounting feature 266 includes an opening 266 a that is configured toreceive a fastener 267 for mounting an angled foot 269 to the z-axissection 218. Although one is shown, the z-axis section 218 may includeany number of the openings 266 a for receiving any number of fasteners.In addition or alternatively to the opening 266 a, the external mountingfeature 266 may include any other structure that enables the supportstructure to be mounted to the z-axis section 218, such as, but notlimited to, a groove, a slot, a keying feature, a clip, a latch, aninterference-fit member, a snap-fit member, and/or the like. Moreover,in addition or alternatively to the external mounting feature 266 on thecorner segment 232, the z-axis section 218 may include one or moreexternal mounting features 266 positioned at another location, forexample along a wall segment 230.

Referring again to FIGS. 11 and 12, the corner segments 232 and the wallsegments 230 connect together in an alternating arrangement to form thez-axis section 218. The z-axis section 218 can then be used alone orarranged within a stack with other z-axis sections 218 to build thecorresponding electronics enclosure. For example, FIG. 14 is aperspective view of yet another exemplary embodiment of a z-axis section318. The z-axis section 318 is defined by a plurality of modular cornersegments 332 and a plurality of modular wall segments 330 that connecttogether in an alternating arrangement to form the z-axis section 318.Specifically, free ends 344 of the wall segments 330 are received withinthe corresponding receiver socket 348 of the corresponding cornersegment 332 such that the corner segments 332 and the wall segments 330are mechanically connected together at the interfaces between the freeends 344 and the receiver sockets 348. The corner segments 332 and thewall segments 330 are thus connected together in an alternatingarrangement to form a continuous ring that defines the z-axis section318, as shown in FIG. 14. The z-axis section 318 can then be used aloneor arranged within a stack with other z-axis sections 318 to build anelectronics enclosure 310 (FIG. 15).

Although four of each are shown, any number of corner segments 332 andany number of the wall segments 330 may be connected together to definethe z-axis section 318, which may have any other shape than the squareshape shown herein. The z-axis section 318 may be referred to herein asa “first”, a “second”, and/or a “third” z-axis section. Moreover, thez-axis section 318 may be referred to herein as an “additional” z-axissection. Each wall segment 330 may be referred to herein as a “first”and/or a “second” wall segment. Each corner segment 332 may be referredto herein as a “first” and/or a “second” corner segment. Each receiversocket 348 may be referred to herein as a “first” and/or a “second”receiver socket.

In the exemplary embodiment of the z-axis section 318, the cornersegments 332 include external mounting feature 366 for mounting of oneor more support structures to the electronics enclosure 310 of thez-axis section 318, for example to facilitate supporting, mounting,compression, and/or the like of the electronics enclosure. In theexemplary embodiment of the z-axis section 318, the external mountingfeatures 366 are grooves 366 a that are configured to receive a key 372(FIG. 15) of a support rail 373 (FIG. 15) for mounting the support rail373 to the z-axis section 318. In addition or alternatively to thegroove 366 a, the external mounting feature 366 may include any otherstructure that enables the support structure to be mounted to the z-axissection 318, such as, but not limited to, an opening that receives afastener, a clip, a slot, a latch, an interference-fit member, asnap-fit member, and/or the like. Moreover, in addition or alternativelyto the external mounting feature 366 on the corner segment 332, thez-axis section 318 may include one or more external mounting features366 positioned at another location, for example along a wall segment330.

FIG. 15 is a perspective view of an exemplary embodiment of theelectronics enclosure 310. The electronics enclosure 310 is formed byone or more z-axis sections 318. The z-axis dimension of the electronicsenclosure 310 may be pre-selected by selecting the number of z-axissections 318 that make up the stack 320. In the exemplary embodiment,the electronics enclosure 310 includes seven z-axis sections 318arranged within the stack 320. But, the electronics enclosure 310 mayinclude any number of z-axis sections 318. The z-axis dimension of theelectronics enclosure 310 is scalable by selecting the number of z-axissections 318 that are stacked on top of each other. In other words, thez-axis sections 318 are modular sections that provide standard (i.e.,universal) building blocks that can be stacked together in any number tobuild an electronics enclosure 310 having any z-axis dimension. Theinternal cavity 356 of each z-axis section 318 defines a correspondingportion of the internal compartment 314 of the electronics enclosure310. At least one of the z-axis sections 318 holds an electronic device16, while at least one of the z-axis sections 318 includes a cover 326.

In the exemplary embodiment of the electronics enclosure 310, theelectronics enclosure 310 has the overall shape of parallelepiped. But,the overall shape of the electronics enclosure 310 is not limited to aparallelepiped shape, nor are the z-axis sections 318 limited to asquare shape. Rather, the z-axis sections 318 may have any other shapein the x-y plane and the electronics enclosure 310 may have any otheroverall shape.

The electronics enclosure 310 is shown in FIG. 15 as including aplurality of the optional support rails 373 mounted on the grooves 366 ato facilitate supporting, mounting, compression, and/or the like of theelectronics enclosure 310. Each support rail 373 extends along thez-axis of the enclosure 10 and is mounted to all of the z-axis sections18 to hold the z-axis sections 18 together in the stack 20. As shown inFIG. 15, one or more of the support rails 373 optionally includes a foot377 for supporting the enclosure 310 on a surface. Optionally, thesupport rails 373 are clamps that include two members 373 a and 373 bthat clamp to the corner segments 332 of the z-axis sections 318, as isshown in FIG. 15.

FIG. 16 is a perspective view of another exemplary embodiment of anelectronics enclosure 410. FIG. 17 is an exploded perspective view ofthe electronics enclosure 410. Referring now to FIGS. 16 and 17, theelectronics enclosure 410 is formed by one or more z-axis sections 418.Each z-axis section 418 is substantially similar to the z-axis sections318 (FIGS. 14 and 15), except at least some of the modular wall segments430 of the z-axis sections 418 are shared between two or more z-axissections 418. Specifically, at least some of the wall segments 430 aremechanically connected to the modular corner segments 432 of more thanone z-axis section 418. In the exemplary embodiment of the electronicsenclosure 410, wall segments 430 a are shared by interior z-axissections 418 a, 418 b, 418 c, and 418 d of the electronics enclosure410. Each wall segment 430 may be shared by any number of z-axissections 418. Optionally, one or more of the z-axis sections 418 doesnot include a wall segment 430 that is shared by another z-axis section418. For example, the wall segments 430 b of end z-axis sections 418 eand 418 f of the electronics enclosure 410 are not shared by anotherz-axis section 418.

As can be seen in FIGS. 16 and 17, the z-axis sections 418 includeexternal mounting features 466 in the form of angled foot receivers 466a that receive angled feet 469 (FIG. 16) therein. The angled feet 469optionally include compressible members 471 that are compressed as theyare received within the corresponding receiver 466 a to create aninterference fit therebetween that holds the angled foot 469 within thecorresponding receiver 466 a. As shown in FIG. 16, the angled feet 469optionally extend along and are optionally mounted to a plurality of thez-axis sections 418 to hold the z-axis sections 18 together in the stack20.

FIG. 18 is a perspective view of an exemplary embodiment of a modularextension construction unit 728. The extension construction unit 728includes two receiver sockets 748. The extension construction unit 728is configured to be used with the wall segment 230 (FIGS. 11-13) and/or330 (FIGS. 14 and 15), which include the free ends 244 and 344,respectively. The receiver sockets 748 of the modular extensionconstruction unit 728 are each configured to receive the free end 244 or344 of a corresponding wall segment 230 or 330, respectively. As shownin FIG. 18, the receiver sockets 748 of the extension construction unit728 have an angle of approximately 0° relative to each other such thatthe entirety of the length of the extension one piece construction unit728 is approximately straight. The construction unit 728 optionallyincludes one or more of the internal mounting features (not shown) formounting one or more electronic and/or other devices 16 (FIGS. 6 and 10)to the extension construction unit 728. Moreover, the extensionconstruction unit 728 optionally includes a strengthening boss (notshown) that may add rigidity and/or strength to the enclosure 10 byforming a reinforcing rib that extends along the z-axis.

The extension construction unit 728 may be used with one or more wallsegments 230 or 330 along one or more of sidewalls of the electronicsenclosure 310 (FIG. 15). Specifically, the extension construction unit728 may be connected with one or more wall segments 230 or 330 withinthe ring of a z-axis section 318 (FIGS. 14 and 15) of the electronicsenclosure 310 to extend the maximum x-axis and y-axis dimensions towhich the z-axis section 318, and thus the electronics enclosure 310, iscapable of being built. It should be understood that in embodiments thatinclude one or more extension construction units 728, the extensionconstruction unit 728 interrupts the alternating arrangement of thecorner segments (e.g., the corner segments 232 and 332) and the wallsegments of the corresponding z-axis section (e.g., the z-axis section318). Moreover, the extension construction unit 728 may have a heightalong the z-axis that spans two or more z-axis sections of theenclosure, such that the extension construction unit 728 may be usedwith, for example, the enclosure 410 (FIGS. 16 and 17). The height ofthe extension construction unit 728 may span any number of z-axissections of the enclosure, whether or not the number of z-axis sectionsspanned by the extension construction unit 728 is the same or differentthan the overall number of z-axis sections that define the enclosure 10(i.e., the number of z-axis sections that the enclosure includes).

The enclosures described and/or illustrated herein (e.g., the enclosures10, 310, and 410) may include one or more partitions that divide theinternal cavity (e.g., the internal cavity 56, 256, and 356) of one ormore of the z-axis sections (e.g., the z-axis sections 18, 218, 318, and418) into two or more sub-cavities. For example, FIG. 19 is a plan viewof an exemplary embodiment of a z-axis section 518 that includes anexemplary embodiment of a partition 520. The exemplary embodiment of thez-axis section 518 includes a plurality of modular corner segments 532and a plurality of modular wall segments 530 that connect together inthe x-y plane to define an internal cavity 556 of the z-axis section518. The corner segments 532 and the wall segments 530 connect togetherin an alternating arrangement to form the z-axis section 518. The z-axissection 518 can then be used alone or arranged within a stack with otherz-axis sections 518 to build an enclosure (not shown), wherein theinternal cavity 556 of the z-axis section 518 defines at least a portionof an internal compartment (not shown) of the enclosure. The z-axissection 518 may be referred to herein as a “first”, a “second”, and/or a“third” z-axis section. Moreover, the z-axis section 518 may be referredto herein as an “additional” z-axis section.

The exemplary embodiment of the partition 520 divides an internal cavity556 of the z-axis section 518 into two sub-cavities 556 a and 556 b. Thepartition 520 is held in place by modular partition construction units528 that are each interconnected between the free ends 544 of twoadjacent corresponding wall segments 530 of the z-axis section 518.Alternatively, a wall segment 530 of the z-axis section 518 is severedalong the length of the wall segment 530 and a partition constructionunit 528 is interconnected between the severed ends of the wall segment530.

FIG. 20 is a perspective view of an exemplary embodiment of a partitionconstruction unit 528. Referring now to FIGS. 19 and 20, each partitionconstruction unit 528 includes two receiver sockets 548. The receiversockets 548 are each configured to receive the free end 544 of acorresponding wall segment 530. As shown in FIGS. 19 and 20, in theexemplary embodiment, the receiver sockets 548 of the partitionconstruction unit 528 have an angle of approximately 0° (i.e.,approximately parallel) relative to each other.

The partition construction unit 528 includes a partition socket 519,which as can be seen in FIG. 19 receives a corresponding free end 521 ofthe partition 520 therein. Reception of the free ends 521 within thecorresponding partition socket 519 mechanically connects the partition520 to the partition construction unit 528. Each free end 521 isoptionally received within the corresponding partition socket 519 withan interference and/or snap fit. For example, the interference and/orsnap fit may be provided by a detent arrangement, a dimple/divotarrangement, a bar/groove arrangement, another arrangement, and/or thelike. Whether or not the free end 521 is received within thecorresponding partition socket 519 with an interference and/or snap fit,one or more other structures and/or materials is optionally used tostrengthen the mechanical connection at, and/or seal, the interfacebetween the free end 521 and the corresponding partition socket 519,such as, but not limited to, a weld, an adhesive, a fastener, a clip, alatch, a clamp, and/or the like. In some embodiments, the adhesive is anactivatable adhesive system.

In the exemplary embodiment, the partition socket 519 extendsapproximately perpendicular (i.e., approximately 90°) to the receiversockets 548, as can be seen in FIG. 19. The approximately parallelorientation of the receiver sockets 548 and the approximatelyperpendicular orientation of the partition socket 519 (relative to theapproximately parallel receiver sockets 548) provides the partitionconstruction unit 528 with a “T” shape in the exemplary embodiment. But,the partition socket 519 may extend at any other angle relative to thereceiver sockets 548, such as, but not limited to, between approximately10° and approximately 170°.

Each partition construction unit 528 optionally includes one or more ofthe internal mounting features (not shown) for mounting one or moreelectronic and/or other devices 16 (FIGS. 6 and 10) to the partitionconstruction unit 528. Moreover, each partition construction unit 528optionally includes a strengthening boss (not shown) that may addrigidity and/or strength to the corresponding enclosure by forming areinforcing rib that extends along the z-axis. Each partitionconstruction unit 528 optionally includes one or more stacking features562 (not shown in FIG. 19) for stacking the z-axis section 518 onanother z-axis section. It should be understood that in embodiments thatinclude one or more partition construction units 528 wherein one or morepartition construction units 528 is interconnected between two adjacentwall segments 530, the partition construction unit(s) 528 interrupts thealternating arrangement of the corner segments 532 and the wall segments530 of the z-axis section 518.

Referring again solely to FIG. 19, the exemplary embodiment of thez-axis section 518 includes two partition construction units 528 a and528 b. In the exemplary embodiment, the partition construction unit 528a is interconnected between wall segments 530 a and 530 b of the z-axissection 518, and the partition construction unit 528 b is interconnectedbetween wall segments 530 c and 530 d of the z-axis section 518 thatgenerally oppose the wall segments 530 a and 530 b. Free ends 521 a and521 b of the partition 520 are received within respective partitionsockets 519 a and 519 b of the partition construction 528 a and 528 b,respectively. The partition 520 spans the internal cavity 556 of thez-axis section 518 from the partition construction unit 528 a to thepartition construction unit 528 b. The partition 520 thereby divides theinternal cavity 556 into the two sub-cavities 556 a and 556 b of thez-axis section 518.

In the exemplary embodiment, the z-axis section 518 includes a singlepartition 520 that divides the internal cavity 556 of the z-axis section518 into two sub-cavities 556 a and 556 b. But, the z-axis section 518may include any number of partitions 520 for dividing the internalcavity 556 into any number of sub-cavities. Each sub-cavity may have anysize and any shape. Moreover, although a length of the partition 520 isshown as extending approximately straight (e.g., between the partitionconstruction units 528 a and 528 b) in the exemplary embodiment,additionally or alternatively the length of each partition 520 mayinclude any other shape. For example, a partition 520 may be angledshape and/or curved along the length of the partition 520. The z-axissection 518 is not limited to the pattern (i.e., relative shape,relative size, relative position, relative location, relativeorientation, and/or the like) of the sub-cavities 556 a and 556 b shownherein. Rather, the z-axis section 518 may additionally or alternativelyinclude any other pattern of sub-cavities. Optionally, one or more ofthe partition(s) 520 includes a cover (not shown) that defines a z-axisboundary of the sub-cavity defined by the partition(s) 520.

In embodiments wherein the z-axis section 518 includes more than onepartition 520, free ends 521 of different partitions 520 may beinterconnected to provide a continuous divider within the internalcavity 556 of the z-axis section 518. The free ends 521 of differentpartitions 520 may be interconnected using modular internal partitionconstruction units (not shown) that are similar to the partitionconstruction units 528 and the corner segments 532. Specifically, theinternal partition construction units include at least two partitionsockets 519 that receive the free ends 521 of the different partitions520. Each internal partition construction unit may include any number ofpartition sockets 519 for interconnecting any number of differentpartitions 520. Moreover, the partition sockets 519 of an internalpartition construction unit may extend at any angle relative to eachother (i.e., may have any pattern). For example, each internal partitionconstruction unit may include, but not limited to including, twopartition sockets 519 for interconnecting two different partitions 520(e.g., two partition sockets 519 that are angled approximately parallel,approximately perpendicular, or at an oblique angle relative to eachother), three partition sockets 519 for interconnecting three differentpartitions 520 (e.g., three partition sockets 519 that define a “T”shape or define another shape), four partition sockets 519 forinterconnecting four different partitions 520 (e.g., four partitionsockets 519 that define a cross shape or define another shape), and/orthe like.

Optionally, in addition or alternatively to the partitions 520, thez-axis section 518 includes one or more partitions (not shown) thatextend along an exterior side 523 of the z-axis section 518 instead ofwithin the internal cavity 556, for example for providing a partitionbetween the enclosure defined by the z-axis section 518 and anotherenclosure. Although shown as extending only along the z-axis section518, each partition 520 may extend along any number of z-axis sectionsof the enclosure that includes the z-axis section 518. In other words,each partition 520 may extend along any amount of the z-axis dimensionof the enclosure that includes the z-axis section 518. For example, insome embodiments, one or more partitions 520 extends along anapproximate entirety of the z-axis dimension of the enclosure.

Although shown as used with a z-axis section 518 having corner segments532 and wall segments 530, the partitions described and/or illustratedherein may be used with an enclosure and/or z-axis section describedand/or illustrated herein (e.g., with an z-axis section that includes aconstruction unit that includes both a receiver socket and a wallsegment, such as, but not limited to, the construction units 28 shownand described herein).

In some embodiments, a kit is provided for forming an electronicsenclosure. The kit includes a plurality of modular construction unitsthat connect together to at least partially define an internalcompartment of the electronics enclosure. Each construction unitincludes a wall segment extending a length from a corner end to a freeend, and a corner segment extending outward from the corner end of thewall segment. The corner segment is integrally formed with the wallsegment. The corner segment includes a receiver socket that isconfigured to receive the free end of another corresponding constructionunit therein to connect the construction units together. Sub-groups ofthe construction units connect together one after the other with achasing symmetry to define z-axis sections that are stackable to formthe electronics enclosure. The kit may include all the pieces needed toconstruct an enclosure between a minimal set of dimensions up to amaximum combined set of dimensions. Multiple sized kits may be done toallow for different maximum dimensions. The kit may include, in additionto standard wall components, items such as universal internal mounts,outer mounting rails, and/or adhesive systems.

The embodiments described and/or illustrated herein describes modularconstruction units that provide standard (i.e., universal) buildingblocks that can be connected together to build a z-axis section of anysize and shape. The modular z-axis sections of the embodiments describedand/or illustrated herein provide standard (i.e., universal) buildingblocks that can be stacked together in any number to build anelectronics enclosure having any z-axis dimension. The embodimentsdescribed and/or illustrated herein thus provide modular constructionunits that can be connected together to build an electronics enclosurehaving any size and shape. The embodiments described and/or illustratedherein may enable relatively rapid manufacturing of a new electronicsenclosure from stock pieces on hand to any desired dimensions.

The construction units of the embodiments described and/or illustratedherein may be fabricated from the same mold or extrusion die, which mayeliminate the need to provide different molds and/or dies for producingdifferently sized and/or shaped electronics enclosures. Moreover, theconstruction units described and/or illustrated herein may enableaccelerated production of different electronics enclosures byeliminating the time it takes to fabricate such additional molds and/ordies.

The embodiments described and/or illustrated herein may provide anelectronics enclosure that has an increased rigidity and/or a decreasednumber of joints as compared to at least some known electronicsenclosures. The embodiments described and/or illustrated herein mayprovide an electronics enclosure that has a reduced weight as comparedto at least some known electronics enclosures. The embodiments describedand/or illustrated herein may provide an electronics enclosure havingone or more covers that adequately closes an open end, top, and/orbottom of the enclosure.

As used herein, the term “ring” is not limited to a circular orotherwise curved shape. As used herein, an element or step recited inthe singular and proceeded with the word “a” or “an” should beunderstood as not excluding plural of said elements or steps, unlesssuch exclusion is explicitly stated. Furthermore, references to “oneembodiment” or “an embodiment” are not intended to be interpreted asexcluding the existence of additional embodiments that also incorporatethe recited features. Moreover, unless explicitly stated to thecontrary, embodiments “comprising” or “having” an element or a pluralityof elements having a particular property may include additional elementsnot having that property.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the inventionwithout departing from its scope. Dimensions, types of materials,orientations of the various components, and the number and positions ofthe various components described herein are intended to defineparameters of certain embodiments, and are by no means limiting and aremerely exemplary embodiments. Many other embodiments and modificationswithin the spirit and scope of the claims will be apparent to those ofskill in the art upon reviewing the above description. The scope of theinvention should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. In the appended claims, the terms “including” and“in which” are used as the plain-English equivalents of the respectiveterms “comprising” and “wherein.” Moreover, in the following claims, theterms “first,” “second,” and “third,” etc. are used merely as labels,and are not intended to impose numerical requirements on their objects.Further, the limitations of the following claims are not written inmeans—plus-function format and are not intended to be interpreted basedon 35 U.S.C. §112, sixth paragraph, unless and until such claimlimitations expressly use the phrase “means for” followed by a statementof function void of further structure.

What is claimed is:
 1. An enclosure comprising: a plurality of modularcorner segments and a plurality of modular wall segments that connecttogether to at least partially define an internal compartment of theenclosure; the wall segments extending lengths between opposite freeends, at least a majority of the wall segments being fabricated from apolymer; each corner segment comprising opposite first and secondreceiver sockets that are each configured to receive a correspondingfree end of a corresponding wall segment therein to connect the cornersegment to the corresponding wall segments, at least a majority of thecorner segments being fabricated from a polymer; and wherein the cornersegments and the wall segments connect together to define the internalcompartment of the enclosure.
 2. The enclosure of claim 1, wherein thecorner and wall segments are first corner segment and first wallsegments that connect together to define a first z-axis section of theenclosure, the enclosure further comprising a second z-axis sectionformed by a plurality of second corner segments and a plurality ofsecond wall segments, the first and second z-axis sections beingarranged in a stack.
 3. The enclosure of claim 1, wherein at least oneof the corner segments is fabricated from one or more differentmaterials from at least one of one or more other corner segments or oneor more wall segments.
 4. The enclosure of claim 1, wherein the cornerand wall segments are first corner segment and first wall segments thatconnect together to define a first z-axis section of the enclosure, theenclosure further comprising a second z-axis section formed by aplurality of second corner segments and a plurality of second wallsegments, the first and second z-axis sections being arranged in astack, the second z-axis section comprising a cover that provides aboundary for the internal compartment.
 5. The enclosure of claim 1,wherein the enclosure has an x-axis dimension and a y-axis dimension,the x axis and y axis dimensions being scalable by trimming the lengthof the wall segments.
 6. The enclosure of claim 1, wherein the enclosurehas an x-axis dimension, a y-axis dimension, and a z-axis dimension, thecorner segments and wall segments connecting together to define a firstz-axis section of the enclosure, the z-axis dimension of the enclosurebeing scalable by stacking one or more additional z-axis sections on thefirst z-axis section.
 7. The enclosure of claim 1, wherein the cornersegments and wall segments connect together within an x-y plane, theenclosure being defined by at least three sides within the x-y plane. 8.The enclosure of claim 1, wherein the first and second receiver socketsof each corner segment extend at an angle of between approximately 0°and approximately 180° relative to each other.
 9. The enclosure of claim1, wherein the corner segments and wall segments connect together todefine a z-axis section of the enclosure that includes at least onecorner segment and at least one wall segment.
 10. The enclosure of claim1, wherein the enclosure includes four of the walls segments and four ofthe corner segments that connect together to define a z-axis section ofthe enclosure such that the z-axis section has a four-sided shape. 11.The enclosure of claim 1, wherein the corner segments and wall segmentsconnect together within an x-y plane to define a z-axis section of theenclosure, the z-axis section comprising a curved shape in the x-yplane.
 12. The enclosure of claim 1, wherein the corner segments andwall segments connect together to define a z-axis section of theenclosure that has a cylindrical shape or the shape of a parallelepiped.13. The enclosure of claim 1, wherein the corner segments and wallsegments connect together within an x-y plane to define a z-axis sectionof the enclosure, the z-axis section comprising both a convex exteriorcorner and a concave exterior corner.
 14. The enclosure of claim 1,wherein the corner and wall segments connect together to define a firstz-axis section of the enclosure, the corner and wall segments comprisingstacking features for at least one of stacking the first z-axis sectionon another z-axis section of the enclosure or stacking another thez-axis section of the enclosure on the first z-axis section.
 15. Theenclosure of claim 1, wherein the corner and wall segments are firstcorner segments and first wall segments that connect together to definea first z-axis section of the enclosure, the enclosure further comprisesa second z-axis section formed by a plurality of second corner segmentsand second wall segments, the first and second z-axis sections arearranged in a stack with an electromagnetic interference (EMI) barrierextending between the first and second z-axis sections, the free ends ofthe first wall segments are mechanically connected to the correspondingreceiver sockets of the corresponding first corner segments using anelectrically conductive material, and free ends of the second wallsegments are mechanically connected to corresponding receiver sockets ofthe corresponding second corner segments using an electricallyconductive material.
 16. The enclosure of claim 1, wherein the cornerand wall segments are first corner segments and first wall segments thatconnect together to define a first z-axis section of the enclosure, theenclosure further comprises a second z-axis section formed by aplurality of second corner segments and second wall segments, the firstand second z-axis sections being arranged in a stack and beingmechanically connected together using at least one of fasteners, welds,or adhesive.
 17. The enclosure of claim 1, wherein the free ends of thewall segments are mechanically connected to the corresponding first orsecond receiver socket of the corresponding construction unit using atleast one of a weld, an adhesive, an interference fit, or a snap fit.18. The enclosure of claim 1, wherein the corner segments compriseinternal mounting features for mounting an electronic device within theinternal compartment.
 19. The enclosure of claim 1, wherein the cornersegments comprise external mounting features for mounting at least oneof a support foot or a support rail to the enclosure.
 20. The enclosureof claim 1, wherein at least one of: at least one of the corner segmentsis at least one of electrically conductive or thermally conductive; orat least one of the wall segments is at least one of electricallyconductive or thermally conductive.
 21. The enclosure of claim 1,wherein each corner segment and each wall segment that is fabricatedfrom a polymer is fabricated at least approximately 90% from thepolymer.